SUBSTRATE STRUCTURE AND METHOD FOR MANUFACTURING THE SAME
A substrate structure includes a wiring structure, a first bump pad, a second bump pad and a compensation structure. The wiring structure includes a plurality of redistribution layers. The first bump pad and the second bump pad are bonded to and electrically connected to the wiring structure. An amount of redistribution layers disposed under the first bump pad is greater than an amount of redistribution layers disposed under the second bump pad. The compensation structure is disposed under the second bump pad.
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This application is a continuation of U.S. patent application Ser. No. 16/942,579 filed Jul. 29, 2020, now U.S. Pat. No. 11,289,411, which application is a continuation of U.S. patent application Ser. No. 16/774,161 filed Jan. 28, 2020, now U.S. Pat. No. 10,741,483 the contents of all such applications being incorporated herein by reference in their entirety.
BACKGROUND 1. Field of the DisclosureThe present disclosure relates to a substrate structure and a method, and to a substrate structure including a compensation structure, and a method for manufacturing the substrate structure.
2. Description of the Related ArtA substrate structure may include a dielectric structure, a plurality of redistribution layer embedded in the dielectric structure, and a plurality of bump pads disposed on the dielectric structure and electrically connected to the redistribution layers. The dielectric structure includes a plurality of dielectric layers. However, due to the layout of the redistribution layers, a top surface of each of the dielectric layers that covers the redistribution layer may not be flat or planar. Thus, a top surface of the dielectric structure may not be flat or planar. Accordingly, the bump pads disposed thereon may not be at a same level. Due to the level differences between these bump pads, a semiconductor die may not be properly connected to each of the bump pads of the substrate structure.
SUMMARYIn some embodiments, a substrate structure includes a wiring structure, a first bump pad, a second bump pad and a compensation structure. The wiring structure includes a plurality of redistribution layers. The first bump pad and the second bump pad are bonded to and electrically connected to the wiring structure. An amount of redistribution layers disposed under the first bump pad is greater than an amount of redistribution layers disposed under the second bump pad. The compensation structure is disposed under the second bump pad.
In some embodiments, a substrate structure includes a wiring structure, a bump pad and a dummy metal layer. The wiring structure includes a dielectric layer and a redistribution layer disposed on the dielectric layer. The bump pad is bonded to and electrically connected to the wiring structure. The bump pad has a projection region on the dielectric layer. The projection region of the bump pad has a first area. A portion of the redistribution layer is disposed within the projection region of the bump pad. The portion of the redistribution layer in the projection region has a second area. The second area is less than 40% of the first area. The dummy metal layer is disposed on the dielectric layer. At least a portion of the dummy metal layer is disposed within the projection region of the bump pad on the dielectric layer.
In some embodiments, a method for manufacturing a substrate structure includes: (a) providing a wiring structure and a compensation structure, wherein the wiring structure includes a plurality of redistribution layers, an amount of redistribution layers at a position corresponding to a first position is greater than an amount of redistribution layers at a position corresponding to a second position, and the compensation structure is located at the position corresponding to the second position; and (b) forming a first bump pad and a second bump pad on and electrically connected to the wiring structure, wherein the first bump pad and the second bump pad are respectively located at the position corresponding to the first position and the position corresponding to the second position, and the first bump pad and the second bump pad are substantially at a same level.
Aspects of some embodiments of the present disclosure are readily understood from the following detailed description when read with the accompanying figures. It is noted that various structures may not be drawn to scale, and dimensions of the various structures may be arbitrarily increased or reduced for clarity of discussion.
Common reference numerals are used throughout the drawings and the detailed description to indicate the same or similar components. Embodiments of the present disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings.
The following disclosure provides for many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to explain certain aspects of the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed or disposed in direct contact, and may also include embodiments in which additional features may be formed or disposed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
A comparative substrate structure may include a first dielectric layer, a first redistribution layer disposed on the first dielectric layer, a second dielectric layer covering the first redistribution layer, and a second redistribution layer disposed on the second dielectric layer, etc. The substrate structure may further include a plurality of bump pads disposed on a topmost dielectric layer.
In the comparative substrate structure, since the second dielectric layer covers the first redistribution layer, a shape of a top surface of the second dielectric layer may be affected by the first redistribution layer which is a patterned layer. That is, the top surface of the second dielectric layer may not be flat or planar. For example, the top surface of the second dielectric layer may be relatively high at a positon where the first redistribution layer exists, and may be relatively low at a position where the first redistribution is absent. The level difference may accumulate when the amount of the redistribution layers and the dielectric layers increase. In some embodiments, a level difference between a highest position and a lowest position of a top surface of the topmost dielectric layer may be about 4 μm, or even greater. Accordingly, the bump pads disposed on the topmost dielectric layer may not be at a same level, which may adversely affect the bonding quality between the comparative substrate structure and a semiconductor die. For example, the semiconductor die may not be properly connected to each of the bump pads of the substrate structure.
The present disclosure addresses at least some of the above concerns and provides for a substrate structure including a compensation structure for compensating the level difference of the bump pads. Some embodiments of the present disclosure further provides for a method for manufacturing the substrate structure.
The wiring structure 2 includes a plurality of redistribution layers, such as four redistribution layers (e.g., a first redistribution layer 22, a second redistribution layer 24, a third redistribution layer 26, a fourth redistribution layer 28,) as shown in
The first dielectric layer 21 may be a bottommost dielectric layer of the wiring structure 2. As shown in
The first redistribution layer 22 is disposed on the first dielectric layer 21. The first redistribution layer 22 may be a patterned layer that includes at least one conductive trace and at least one conductive pad. As shown in
The second dielectric layer 23 is disposed on the first dielectric layer 21 and covers the first redistribution layer 22. The second dielectric layer 23 may be conformal to the first redistribution 22. For example, the second dielectric layer 23 may be applied in a liquid form by coating, or in a dry film form by laminating. The second dielectric layer 23 may be applied in a constant volume over the entire first dielectric layer 21 to cover the first redistribution layer 22. Hence, the “topography” of the second dielectric layer 23 may be affected by the first redistribution layer 22 disposed thereunder. That is, the “topography” of the second dielectric layer 23 may be ascending at a position where the first redistribution layer 22 exists, and may be descending at a position where the first redistribution layer 22 is absent. Accordingly, a top surface of the second dielectric layer 23 may not be flat or planar. In some embodiments, the top surface of the second dielectric layer 23 may be in a wave shape.
The second redistribution layer 24 is disposed on the second dielectric layer 23. The second redistribution layer 24 may be a patterned layer that includes at least one conductive trace and at least one conductive pad. As shown in
The third dielectric layer 25 is disposed on the second dielectric layer 23 and covers the second redistribution layer 24. The third dielectric layer 25 may be conformal to the second redistribution layer 24 and the second dielectric layer 23. Similar to the second dielectric layer 23 described above, the “topography” of the third dielectric layer 25 may be ascending at a position where the first redistribution layer 22 and second redistribution layer 24 exist, and may be descending at a position where the first redistribution layer 22 and/or the second redistribution layer 24 is omitted. Accordingly, a top surface of the third dielectric layer 25 may not be flat or planar. For example, at a position corresponding to a position P1 shown in
The third redistribution layer 26 is disposed on the third dielectric layer 25. The third redistribution layer 26 may be a patterned layer that includes at least one conductive trace and at least one conductive pad. As shown in
The fourth dielectric layer 27 is disposed on the third dielectric layer 25 and covers the third redistribution layer 26. The fourth dielectric layer 27 may be conformal to the third redistribution layer 26 and the third dielectric layer 25. Similar to the second dielectric layer 23 and the third dielectric layer 25 described above, the “topography” of the fourth dielectric layer 27 may be ascending at a position where the first redistribution layer 22, the second redistribution layer 24 and the third redistribution layer 26 exist, and may be descending at a position where the first redistribution layer 22, the second redistribution layer 24 and/or the third redistribution layer 26 is omitted. Accordingly, a top surface of the fourth dielectric layer 27 may not be flat or planar. For example, at a position corresponding to the position P1 shown in
The fourth redistribution layer 28 is disposed on the fourth dielectric layer 27. The fourth redistribution layer 28 may be a patterned layer that includes at least one conductive trace and at least one conductive pad. As shown in
The fifth dielectric layer 29 is disposed on the fourth dielectric layer 27 and covers the fourth redistribution layer 28. The fifth dielectric layer 29 may be conformal to the fourth redistribution layer 28 and the fourth dielectric layer 27. Similarly, the “topography” of the fifth dielectric layer 29 may be ascending at a position where the first redistribution layer 22, the second redistribution layer 24, the third redistribution layer 26 and the fourth redistribution layer 28 exists, and may be descending at a position where the first redistribution layer 22, the second redistribution layer 24, the third redistribution layer 26 and/or the fourth redistribution layer 28 is omitted. Accordingly, a top surface of the fifth dielectric layer 29 may not be flat or planar. For example, at a position corresponding to the position P1 shown in
In some embodiments, a material of the first dielectric layer 21, the second dielectric layer 23, the third dielectric layer 25, the fourth dielectric layer 27 and/or the fifth dielectric layer 29 may include an insulating material, a passivation material, a dielectric material or a solder resist material, such as, for example, a benzocyclobutene (BCB) based polymer or a polyimide (PI). In some embodiments, the second dielectric layer 23, the third dielectric layer 25, the fourth dielectric layer 27 and/or the fifth dielectric layer 29 may be made of a photoimageable dielectric (PID) material.
In some embodiments, a material of the first redistribution layer 22, the second redistribution layer 24, the third redistribution layer 26 and/or the fourth redistribution layer 28 may be a conductive metal. For example, the first redistribution layer 22, the second redistribution layer 24, the third redistribution layer 26 and/or the fourth redistribution layer 28 may include a seed layer and a conductive layer. A material of the seed layer may be titanium, copper, another metal or an alloy. In some embodiments, the seed layer includes a titanium layer and a copper layer. A material of the conductive layer may include, for example, copper, another conductive metal, or an alloy thereof.
The wiring structure 2 has a first surface 201 and a second surface 202 opposite to the first surface 201. As shown in
As discussed above, the second redistribution layer 24 and the third redistribution layer 26 are absent at a position corresponding to the second position P2. That is, an amount of redistribution layers at a position corresponding to the first position P1 is greater than an amount of redistribution layers at the second position P2. For example, as shown in
As shown in
The first bump pad 31 and the second bump pad 32 are bonded to and electrically connected to the wiring structure 2. As shown in
In some embodiments, the first bump pad 31 and the second bump pad 32 are formed concurrently. It is difficult to form the first bump pad 31 and the second bump pad 32 with different thicknesses. That is, a thickness of the first bump pad 31 may substantially equal to a thickness of the second bump pad 32. The thickness of the first bump pad 31 may be measured from the second surface 202 of the wiring structure 2 to a top surface of the first bump pad 31. Besides, a barrier layer 35 and a wetting layer 36 may be disposed on the first bump pad 31 and the second bump pad 32. A material of the barrier layer 35 may include nickel. A material of the wetting layer 36 may include gold.
The compensation structure (e.g., the intermediate bump 34) is disposed under the second bump pad 32. The intermediate bump 34 is interposed between and electrically connecting the wiring structure 2 and the second bump pad 32. A lateral surface 341 of the intermediate bump 34 may be not coplanar with a lateral surface 321 of the second bump pad 32. A width W2 of the intermediate bump 34 may be greater than a width W1 of the second bump pad 32.
Due to the arrangement of the intermediate bump 34, the first bump pad 31 and the second bump pad 32 are substantially at a same level. In some embodiments, the level of the first bump pad 31 may be measured from the first surface 201 of the wiring structure 2 to the top surface of the first bump pad 31. The level of the second bump pad 32 may be measured from the first surface 201 of the wiring structure 2 to a center of a top surface of the second bump pad 32. However, the top surface of the first bump pad 31 may not be coplanar with the top surface of the second bump pad 32.
In some embodiments, as shown in
As shown in
The first dummy metal layer 37 and the second dummy metal layer 38 are disposed at the position corresponding to the position P2 under the second bump pad 32. As shown in
As shown in
Besides, the aforementioned design rule for dummy metal layers may be applied to each redistribution layer under the bump pad. For example, the second bump pad 32 has a projection region 320 on the third dielectric layer 25a. The projection region 320 of the second bump pad 32 has a first area. A portion of the third redistribution layer 26 is disposed within the projection region 320 of the bump pad 32. The portion of the third redistribution layer 26 in the projection region 320 has a second area. The second area is less than 40% of the first area. That is, as for the third redistribution layer 26, an area of a portion of the third redistribution layer 26 within the projection region 320 of the second bump pad 32 on the third dielectric layer 25a is less than 40% of an area of the projection region 320 of the second bump pad 32 on the third dielectric layer 25a. Accordingly, the second dummy metal layer 38 is disposed on the third dielectric layer 25a for supporting purpose. As shown in
As shown in
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Meanwhile, a wiring structure 2 is obtained. The wiring structure 2 has a first surface 201 and a second surface 202 opposite to the first surface 201. As shown in
As discussed above, the second redistribution layer 24 and the third redistribution layer 26 are absent at the position corresponding to the second position P2. That is, an amount of redistribution layers at the position corresponding to the first position P1 is greater than an amount of redistribution layers at the position corresponding to the second position P2. For example, as shown in
Referring to
Referring to
The second bump pad 32 is disposed on the compensation structure (e.g., the intermediate bump 34). Thus, the intermediate bump 34 is interposed between and electrically connecting the wiring structure 2 and the second bump pad 32. A lateral surface 341 of the intermediate bump 34 may be not coplanar with a lateral surface 321 of the second bump pad 32. A width W2 of the intermediate bump 34 may be greater than a width W1 of the second bump pad 32.
Due to the arrangement of the intermediate bump 34, the first bump pad 31 and the second bump pad 32 are substantially at a same level. In some embodiments, the level of the first bump pad 31 may be measured from the first surface 201 of the wiring structure 2 to the top surface of the first bump pad 31. The level of the second bump pad 32 may be measured from the first surface 201 of the wiring structure 2 to a center of a top surface of the second bump pad 32. However, the top surface of the first bump pad 31 may not be coplanar with the top surface of the second bump pad 32.
Then, the carrier 80 is removed. An external connector 13 is connected to the first conductive via 221 of the first dielectric layer 21. Then, a singulation process may be conducted to the wiring structure 2, thus forming the substrate structure 1 as shown in
Referring to
Referring to
Then, a third redistribution layer 26 is disposed on the third dielectric layer 25a by, for example, plating. Besides, a second dummy metal layer 38 is also formed on the third dielectric layer 25a by, for example, plating. The second dummy metal layer 38 is located at a position corresponding to the position P2. In some embodiments, the second dummy metal layer 38 may be formed concurrently with the third redistribution layer 26. For example, the second dummy metal layer 38 and the third redistribution layer 26 may be formed in a same process with a same material. However, the second dummy metal layer 38 is insulated from the third redistribution layer 26.
Referring to
Then, a fourth redistribution layer 28 and a fifth dielectric layer 29a are sequentially formed on the fourth dielectric layer 27a, thus forming a wiring structure 2a. The formation processes of the fourth redistribution layer 28 and the fifth dielectric layer 29a are similar to those of the fourth redistribution layer 28 and the fifth dielectric layer 29 described in
Then, a first bump pad 31 and a second bump pad 32 are formed on the wiring structure 2a by, for example, plating. The first bump 31 and the second bump 32 are electrically connected to the wiring structure 2a. The first bump 31 and the second bump 32 are respectively located at the position corresponding to the first position P1 and the position corresponding to the second position P2. Due to the arrangement of the first dummy metal layer 37 and/or the second dummy metal layer 38, the first bump pad 31 and the second bump pad 32 are substantially at a same level.
Then, the carrier 80 is removed. An external connector 13 is connected to the first conductive via 221 of the first dielectric layer 21 for external connection purpose. Then, a singulation process may be conducted to the wiring structure 2a, thus forming the substrate structure 1a as shown in
Spatial descriptions, such as “above,” “below,” “up,” “left,” “right,” “down,” “top,” “bottom,” “vertical,” “horizontal,” “side,” “higher,” “lower,” “upper,” “over,” “under,” and so forth, are indicated with respect to the orientation shown in the figures unless otherwise specified. It should be understood that the spatial descriptions used herein are for purposes of illustration only, and that practical implementations of the structures described herein can be spatially arranged in any orientation or manner, provided that the merits of embodiments of this disclosure are not deviated from by such an arrangement.
As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. For example, when used in conjunction with a numerical value, the terms can refer to a range of variation less than or equal to ±10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%. For example, two numerical values can be deemed to be “substantially” the same or equal if a difference between the values is less than or equal to ±10% of an average of the values, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%.
Two surfaces can be deemed to be coplanar or substantially coplanar if a displacement between the two surfaces is no greater than 5 μm, no greater than 2 μm, no greater than 1 μm, or no greater than 0.5 μm.
As used herein, the singular terms “a,” “an,” and “the” may include plural referents unless the context clearly dictates otherwise.
As used herein, the terms “conductive,” “electrically conductive” and “electrical conductivity” refer to an ability to transport an electric current. Electrically conductive materials typically indicate those materials that exhibit little or no opposition to the flow of an electric current. One measure of electrical conductivity is Siemens per meter (S/m). Typically, an electrically conductive material is one having a conductivity greater than approximately 104 S/m, such as at least 105 S/m or at least 106 S/m. The electrical conductivity of a material can sometimes vary with temperature. Unless otherwise specified, the electrical conductivity of a material is measured at room temperature.
Additionally, amounts, ratios, and other numerical values are sometimes presented herein in a range format. It is to be understood that such range format is used for convenience and brevity and should be understood flexibly to include numerical values explicitly specified as limits of a range, but also to include all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified.
While the present disclosure has been described and illustrated with reference to specific embodiments thereof, these descriptions and illustrations are not limiting. It should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present disclosure as defined by the appended claims. The illustrations may not be necessarily drawn to scale. There may be distinctions between the artistic renditions in the present disclosure and the actual apparatus due to manufacturing processes and tolerances. There may be other embodiments of the present disclosure which are not specifically illustrated. The specification and drawings are to be regarded as illustrative rather than restrictive. Modifications may be made to adapt a particular situation, material, composition of matter, method, or process to the objective, spirit and scope of the present disclosure. All such modifications are intended to be within the scope of the claims appended hereto. While the methods disclosed herein have been described with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations are not limitations of the present disclosure.
Claims
1. A substrate structure, comprising:
- a via;
- a first pad non-overlapping with the via in a cross-sectional view;
- a compensation structure supporting the first pad; and
- a conductive layer disposed between the first pad and the compensation structure, and electrically connecting the via and the first pad.
2. The substrate structure of claim 1, further comprising an electronic component connecting the first pad.
3. The substrate structure of claim 2, further comprising a second pad, wherein the via, the first pad, the compensation structure and a portion of the conductive layer are located in a first region, wherein the second pad is located in a second region distinct from the first region, the second pad is substantially level with the first pad and is connected to the electronic component.
4. The substrate structure of claim 1, further comprising a first set of stacked vias under the via.
5. The substrate structure of claim 4, further comprising a redistribution layer, wherein at least a portion of the redistribution layer is disposed under the compensation structure and the first set of stacked vias, wherein the redistribution layer is electrically connected to the conductive layer through the first set of stacked vias.
6. The substrate structure of claim 5, further comprising:
- a first dielectric layer disposed between the redistribution layer and the compensation structure; and
- a second dielectric layer disposed between the compensation structure and the conductive layer.
7. The substrate structure of claim 6, further comprising:
- a third dielectric layer disposed under the redistribution layer; and
- a conductive via extending through the third dielectric layer and non-overlapped with the compensation structure,
- wherein the conductive via electrically connects the redistribution layer with an external connector.
8. The substrate structure of claim 1, further comprising at least one metal layer disposed under the conductive layer, wherein the at least one metal layer includes a first pattern portion connected to the via and a second pattern portion of the compensation structure.
9. The substrate structure of claim 8, further comprising a dielectric layer disposed between the conductive layer and the at least one metal layer, wherein the dielectric layer encapsulates the via.
10. The substrate structure of claim 9, wherein the first pattern portion is separated from the compensation structure by the dielectric layer.
11. A substrate structure, comprising:
- a first conductive layer having a first region and a second region; and
- a first dielectric layer disposed between the first region and the second region of the first conductive layer, wherein a portion of the first dielectric layer descends between the first region and the second region.
12. The substrate structure of claim 11, further comprising:
- a first pad disposed on the first dielectric layer and over the first region;
- a second pad disposed on the first dielectric layer and over the second region; and
- a second conductive layer including a compensation portion supporting the first pad, and a pattern portion under the second region.
13. The substrate structure of claim 12, further comprising:
- a first set of stacked vias non-overlapped with the first pad and disposed under the first region; and
- a second set of stacked vias non-overlapped with the second pad and disposed under the second region.
14. The substrate structure of claim 12, further comprising a second dielectric layer covering the second conductive layer, wherein the pattern portion is separated from the compensation portion by a portion of the second dielectric layer.
15. The substrate structure of claim 11, further comprising:
- a second conductive layer disposed under the first conductive layer;
- a first via extending through the first dielectric layer and electrically connecting the second pad to the second region; and
- a second via non-overlapped with the first via and electrically connecting the second region to the second conductive layer.
16. The substrate structure of claim 15, further comprising:
- a third conductive layer disposed under the second conductive layer;
- a fourth conductive layer disposed under the third conductive layer;
- a third via at least partially overlapped with the second pad and electrically connecting the second conductive layer to the third conductive layer; and
- a fourth via at least partially overlapped with the second via and electrically connecting the third conductive layer to the fourth conductive layer.
17. The substrate structure of claim 16, further comprising:
- a fifth via extending through the first dielectric layer and electrically connecting the first pad to the first region; and
- a sixth via non-overlapped with the fifth via and electrically connecting the first region to the second conductive layer,
- wherein the second conductive layer includes a compensation portion supporting the first pad.
18. A substrate structure, comprising:
- a first conductive layer having a first region and a second region;
- a conductive element disposed under the first region and connected to the first region;
- a supporting structure disposed under the first region; and
- a first dielectric layer disposed between the first region and the supporting structure.
19. The substrate structure of claim 18, further comprising a second conductive layer disposed under the supporting structure and the conductive element, wherein the second conductive layer is electrically connected to the first conductive layer through the conductive element.
20. The substrate structure of claim 19, further comprising a second dielectric layer disposed between the supporting structure and the second conductive layer.
Type: Application
Filed: Mar 29, 2022
Publication Date: Jul 14, 2022
Patent Grant number: 12040261
Applicant: Advanced Semiconductor Engineering, Inc. (Kaohsiung)
Inventors: Syu-Tang LIU (Kaohsiung), Tsung-Tang TSAI (Kaohsiung), Huang-Hsien CHANG (Kaohsiung), Ching-Ju CHEN (Kaohsiung)
Application Number: 17/707,801